Intake Manifold Waterproofing via Nested Recessed and Projecting Structure
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Solution Overview
Problem
Existing waterproof constructions in internal combustion engine intake devices either increase passage resistance or raise production costs, and are prone to damage, while struggling to effectively prevent water drops from entering the negative pressure outlet port.
Innovation Solution
A waterproof construction featuring a recessed portion on the lower passage wall and a projecting portion on the upper passage wall, where the projecting portion is positioned above and between the negative pressure outlet port and the inner surface, with a gap between the projecting portion and the recessed surface, allowing water drops to flow away from the outlet port and reducing passage resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a projecting portion is provided on the inner surface of passage walls to prevent water drops from entering the negative pressure outlet port, then waterproofing effect is improved, but passage resistance of the intake passage is increased and intake efficiency is lowered
Solution Approach 1:
The projecting portion is nested within a recessed portion formed on the inner surface of the passage wall. The recessed portion has a bottom surface that is lower than the inner surface, and the projecting portion extends from the bottom surface toward the intake passage. This nesting arrangement allows the waterproofing structure to be contained within the recessed portion without protruding into the intake passage, thereby preventing water drops from entering the negative pressure outlet port while avoiding increase in passage resistance and maintaining intake efficiency.
2Productivity
If a recessed portion is provided on the inner surface of passage walls to suppress increase in passage resistance, then intake efficiency is improved, but the recessed portion needs to be enlarged to accommodate a baffle plate which projects towards the opening to prevent water drops from entering, restricting disposition of the negative pressure outlet port and increasing production costs
Solution Approach 1:
The harmful function of the baffle plate (blocking water drops) is extracted from the complex baffle plate structure and implemented by the simple projecting portion. The projecting portion is formed directly on the bottom surface of the recessed portion and extends upward to prevent water drops from reaching the negative pressure outlet port opening, eliminating the need for a separate baffle plate and simplifying the overall construction.
Solution Approach 2:
The recessed portion itself serves the dual function of both housing the waterproofing structure and maintaining intake passage efficiency. By forming the projecting portion directly on the bottom surface of the recessed portion, the recessed portion structure provides both the water drop prevention function and the space-saving advantage, eliminating the need for additional baffle plates and reducing construction complexity.
3Reliability
If a projecting portion is provided on passage walls to make up the waterproof construction, then waterproofing effect is improved, but the projecting portion may be damaged when handling the passage wall
Solution Approach 1:
The projecting portion is nested within the recessed portion, which is formed on the inner surface of the passage wall. The recessed portion provides a protective cavity that shields the projecting portion from external impacts and damage during handling and installation. The projecting portion is thus protected by the recessed portion structure, maintaining its waterproofing function while improving handling ease.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances intake efficiency by minimizing passage resistance, reduces production costs, and prevents water drops from entering the negative pressure outlet port, ensuring effective negative pressure extraction while maintaining a compact and damage-resistant design.
Implementation Method 1
water drops which flow downwards along the inner surface is guided so as not to reach the negative pressure outlet port by a rising surface of the projecting portion
Data Source
AI summary
An intake passage is formed by connecting upper and lower cases 10, 20 of an intake manifold. The lower case 10 has a recessed portion 50 on an inner surface 17a. The recessed portion 50 has a deep surface 53 to which a negative pressure outlet port 42 opens, and an opening 51 is provided in an upper portion of the recessed portion 50. The upper case 20 has a projecting portion 60 extending further downwards towards the negative pressure outlet port 42 than mating surfaces 10a, 20a and projects into the recessed portion 50 through an opening 52. The projecting portion 60 is positioned above the negative pressure outlet port 42 and between the negative pressure outlet port 42 and the inner surface 17a. A lower end portion 63 of the projecting portion 60 is formed into an arc-like shape of which central portion 65 projects downwards.